Mitsubishi Pajero Sport 1999 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Year: 1999 Codes Chassis Code: K90 Series Body Style: SUV 👋 Introduction Market Position Segment: Mid-size SUV, often marketed as a more rugged and off-road capable alternative to unibody SUVs. Competitive Analysis Competitors 1999: Toyota 4Runner, Nissan Pathfinder, Jeep Cherokee (XJ), Ford Explorer, Chevrolet Blazer. Key Features Off Road Capability: Body-on-frame construction, available 4WD/AWD systems, good ground clearance, robust suspension contribute to strong off-road performance. Powertrain Options: Known for reliable V6 gasoline engines, offering a balance of power and refinement for its class. Durability: Designed for durability and longevity, making it a popular choice for those seeking a capable and dependable SUV. 📋 Manual Details Coverage Areas Regions Covered: Global (with potential regional variations noted) Page Count Estimated Page Count: Comprehensive (typically 1000+ pages for full service manuals) Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, fuel system, exhaust system, cooling system, lubrication system, ignition system, emissions control. Drivetrain: Transmission (manual & automatic), transfer case, driveshafts, differentials, axles, hubs, CV joints. Suspension Steering: Front suspension, rear suspension, shock absorbers, springs, control arms, steering gear, power steering system, steering column. Brakes: Front brakes (discs), rear brakes (drums/discs), ABS system, parking brake, brake hydraulics, brake lines, master cylinder, calipers, rotors. Electrical: Battery, charging system (alternator, starter), ignition switch, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams, instrument cluster, body control module (BCM). Body Chassis: Body panels, doors, hood, tailgate, bumpers, interior trim, glass, chassis frame, rust prevention. HVAC: Heating, ventilation, air conditioning (compressor, condenser, evaporator, refrigerant, blower motor, controls). Safety Features: Airbags, seat belts, rollover protection (if applicable). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, battery maintenance. Repair Rebuild: Engine overhauls, transmission rebuilds, brake system repairs, suspension component replacement, electrical system troubleshooting and repair. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting charts, fault code interpretation. Diagnostics: On-board diagnostics (OBD-II), sensor testing, actuator testing. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text (depending on scan quality of original). Print Quality Printability: Printable (standard PDF format). Binding Type Binding: Not applicable (digital format). Paper Type Paper Quality: Not applicable (digital format). ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated SOHC V6 Displacement: 3.0 Liters (approx. 2972 cc) Engine Code: 6G72 (common designation for Mitsubishi 3.0L V6) Performance Horsepower: Approximately 175-185 HP (depending on specific market tune) Torque: Approximately 240-250 Nm (depending on specific market tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Octane rating as per owner's manual recommendations) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: 4-Speed Automatic Transmission with Overdrive Features Transfer Case: Super Select 4WD system (or similar, depending on market), offering 2H, 4H, 4HLC (with locked center diff), 4LLC (with locked center diff and low range). 📐 Dimensions Exterior Length: Approximately 4600-4700 mm (depending on body style/bumper variations) Width: Approximately 1775-1800 mm Height: Approximately 1770-1800 mm Wheelbase: Approximately 2725 mm Weights Curb Weight: Approximately 1800-2000 kg (depending on configuration) Gross Vehicle Weight Rating: Typically around 2400-2600 kg 🛡️ Safety Features Ratings Crash Test Results: Information specific to 1999 may vary by region; refer to NHTSA/Euro NCAP for comparable era vehicles. Active Features ABS: Available Anti-lock Braking System (ABS) Passive Features Airbags: Driver and Passenger Airbags Seatbelts: Three-point inertia-reel seat belts 💡 Technology Features Infotainment Audio System: Factory-installed radio/cassette player or CD player with basic speaker system. Aftermarket upgrades are common. Climate Control: Manual or automatic climate control systems depending on trim level. Driver Assistance Cruise Control: Available cruise control system. Connectivity Power Accessories: Power windows, power door locks, power mirrors. 🔧 Maintenance Service Intervals Oil Change: Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for exact specification). Engine Oil Filter: Replace at every oil change. Air Filter: Inspect every 7,500 miles (12,000 km), replace as needed (typically every 15,000-30,000 miles). Fuel Filter: Replace approximately every 30,000 miles (48,000 km) or as specified. Spark Plugs: Replace based on mileage or time interval (e.g., 60,000-100,000 miles for iridium plugs if equipped, check manual for original spec). Transmission Fluid Manual: Inspect fluid level regularly, change interval typically around 30,000-60,000 miles. Transmission Fluid Automatic: Inspect fluid level and condition regularly. Change interval typically 30,000-60,000 miles, depending on driving conditions. Coolant: Flush and replace every 24-36 months or 30,000-50,000 miles. Fluid Specifications Engine Oil: API SG or higher, SAE 10W-30 or 5W-30 (refer to manual for viscosity based on temperature). Transmission Fluid Automatic: Mitsubishi Diaqueen SP-III or equivalent DEXRON-III/MERCON. Transfer Case Fluid: API GL-4 SAE 75W-90 Gear Oil (check manual for specific type). Differential...
Comprehensive from basic maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text (depending on scan quality of original).
Print Quality
Printability:
Printable (standard PDF format).
Binding Type
Binding:
Not applicable (digital format).
Paper Type
Paper Quality:
Not applicable (digital format).
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated SOHC V6
Displacement:
3.0 Liters (approx. 2972 cc)
Engine Code:
6G72 (common designation for Mitsubishi 3.0L V6)
Performance
Horsepower:
Approximately 175-185 HP (depending on specific market tune)
Torque:
Approximately 240-250 Nm (depending on specific market tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating as per owner's manual recommendations)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type:
4-Speed Automatic Transmission with Overdrive
Features
Transfer Case:
Super Select 4WD system (or similar, depending on market), offering 2H, 4H, 4HLC (with locked center diff), 4LLC (with locked center diff and low range).
📐 Dimensions
Exterior
Length:
Approximately 4600-4700 mm (depending on body style/bumper variations)
Width:
Approximately 1775-1800 mm
Height:
Approximately 1770-1800 mm
Wheelbase:
Approximately 2725 mm
Weights
Curb Weight:
Approximately 1800-2000 kg (depending on configuration)
Gross Vehicle Weight Rating:
Typically around 2400-2600 kg
🛡️ Safety Features
Ratings
Crash Test Results:
Information specific to 1999 may vary by region; refer to NHTSA/Euro NCAP for comparable era vehicles.
Active Features
ABS:
Available Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and Passenger Airbags
Seatbelts:
Three-point inertia-reel seat belts
💡 Technology Features
Infotainment
Audio System:
Factory-installed radio/cassette player or CD player with basic speaker system. Aftermarket upgrades are common.
Climate Control:
Manual or automatic climate control systems depending on trim level.
Driver Assistance
Cruise Control:
Available cruise control system.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for exact specification).
Engine Oil Filter:
Replace at every oil change.
Air Filter:
Inspect every 7,500 miles (12,000 km), replace as needed (typically every 15,000-30,000 miles).
Fuel Filter:
Replace approximately every 30,000 miles (48,000 km) or as specified.
Spark Plugs:
Replace based on mileage or time interval (e.g., 60,000-100,000 miles for iridium plugs if equipped, check manual for original spec).
Transmission Fluid Manual:
Inspect fluid level regularly, change interval typically around 30,000-60,000 miles.
Transmission Fluid Automatic:
Inspect fluid level and condition regularly. Change interval typically 30,000-60,000 miles, depending on driving conditions.
Coolant:
Flush and replace every 24-36 months or 30,000-50,000 miles.
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-30 or 5W-30 (refer to manual for viscosity based on temperature).
Transmission Fluid Automatic:
Mitsubishi Diaqueen SP-III or equivalent DEXRON-III/MERCON.
Transfer Case Fluid:
API GL-4 SAE 75W-90 Gear Oil (check manual for specific type).
Differential Fluid:
API GL-5 SAE 80W-90 Gear Oil (check manual for front/rear specific).
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Vibration:
Potential for engine vibration due to aging engine mounts or balance shaft issues in some 6G7x series engines.
Transmission Issues:
Automatic transmission shift quality can degrade over time; regular fluid changes are crucial. Manual transmission clutch wear is normal with use.
4Wd System:
Actuators or sensors in the 4WD system can fail, requiring diagnosis and repair. Regular operation is recommended to prevent seizing.
Rust Corrosion:
Like many vehicles of this era, susceptible to rust, especially in areas with harsh winters or coastal environments. Frame, wheel arches, and rocker panels are common areas.
Suspension Components:
Ball joints, bushings, and tie rod ends can wear out over time, affecting steering and ride quality.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, notably the Pajero (Montero in some markets), dating back to the early 1980s. The Pajero Sport is a derivative, often built on a chassis shared with the Triton/L200 pickup truck.
Model Evolution
Pajero Sport Generation:
This 1999 model represents the first generation of the Pajero Sport, introduced globally in 1996 as the 'Challenger' in some markets. It aimed to offer a more affordable and slightly less opulent alternative to the flagship Pajero.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with potential assembly in other regions depending on market.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While the Pajero Sport itself might not have specific widely publicized awards, the broader Pajero lineage has numerous accolades from off-road publications and events for its capability.
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